Ignition cable probe tool and method of making ignition leads

ABSTRACT

An ignition cable probe tool is shown having a tubular body terminating at one end with an end plug having a bullet shaped head and body stud for inserting into the end of the probe tool. The opposite end of the probe tool has a grip, shown as an annular member surrounding the end of the body of the tool opposite the end into which the end plug is fitted. The method of making an ignition lead from an ignition cable having an exterior insulation and a central conductor comprises the steps of inserting a tubular ignition wire lead probe into a boot, shown as a right angle boot, cutting the cable to length, inserting the cable through the tubular probe and boot and extending therebeyond, stripping the end of the cable extending, reversely folding the conductor over the end of the cable, positioning the terminal in a crimper, inserting the end of the cable with the reversely folded conductor into the terminal, crimping the same, advancing the tubular body of the tube over the crimped end of the conductor, forcing the boot forwardly off the tubular body of the tool and over the conductor, and withdrawing the tool.

United States Patent 91 Shannon Apr. 9, 1974 IGNITION CABLE PROBE TOOL AND METHOD OF MAKING IGNITION LEADS [76] Inventori John K. Shannon, 200 S. Vincennes Cir., Racine, Wis. 53402 [22] Filed: Oct. 13, 1972 [21] Appl. No.: 297,234

[52] US. Cl 29/628, 29/203 H, 29/235, 29/450 [51] Int. Cl HOlr 43/00 [58] Field of Search 339/26; 29/628, 629, 630 R, 29/630 A, 203 H, 203 HM, 235, 450

Assistant Examiner.lames R. Duzan Attorney, Agent, or FirmDominik, Knechtel, Godula & Demeur i l [5 7] ABSTRACT An ignition cable probe tool is shown having a tubular body terminating at one end with an end plug having a bullet shaped head and body stud for inserting into the end of the probe tool. The opposite end of the probe tool has a grip, shown as an annular member surrounding the end of the body of the tool opposite the end into which the end plug is fitted. The method of making an ignition lead from an ignition cable having an exterior insulation and a central conductor comprises the steps of inserting a tubular ignition wire lead probe into a boot, shown as a right angle boot, cutting the cable to length, inserting the cable through the tubular probe and boot and extending therebeyond, stripping the end of the cable extending, reversely folding the conductor over the end of the cable, positioning the terminal in a crimper, inserting the end of the cable with the reversely folded conductor into the terminal, crimping the same, advancing the tubular body of the tube over the crimped end of the conductor, forcing the boot forwardly off the tubular body of the tool and over the conductor, and withdrawing the tool.

11 Claims, 12 Drawing Figures 'IIIIIIIIIIII PATENTEDAPR 9mm BBB-2,071

sum 1 BF IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIImIMIIII/IIIIIIII/IIIIIIIIIIIIIIIIIIIM'Illh BACKGROUND OF INVENTION 1. Field of Invention The invention relates to the making of ignition leads or ignition harnesses generally. The tool is a probe or insertion member having a tubular body.

2. Description of Prior Art The prior art relates primarily to the elements em ployed in connection with the method of the present invention and the elements which are useful with the tool. Such elements include ignition cable, preferably having an exterior plastic insulation and an interior graphitic-type wick which serves as a conductor. A crimping tool is employed which also has a stripper and a cutter. The various elements primarily include spark plug terminals and distributor terminals which are generally metallic members susceptible of being anchored to the end of the cable, and boots or nipples respectively for positioning over the spark plug terminals and the distributor terminals to insulate the same and shield the same from contamination and also assist in securing the same in electrical contact with the associated ignition elements such as a spark plug and the distributor. The methods generally employed in making ignition harnesses are automated factory techniques with a plurality of well-coordinated tools.

For the garage operator, or marine repair service, or aircraft repair service, a wide variety of motors require servicing. Oftentimes, particularly with marine facilities, the factory is at a considerable distance, and if the ignition lead is faulty, it must be repaired promptly to return the motor to service. To maintain a stock of ignition leads and harnesses for each and every type of outboard motor, inboard motor, where many are of foreign manufacture, is economically unfeasible, and oftentimes impossible where older units are involved and the manufacturer no longer stocks replacement leads.

SUMMARY The invention relates in part to an ignition cable probe tool having a tubular body which loose-fittingly receives an ignition cable. An end plug is provided with a rounded end and a stud portion to fit snuggly within one end of the tubular body, and the opposite end is provided with a grip. Particularly when leading ignition cable through a right angled boot, the tool may be employed in the method which includes inserting the same through the boot to straighten out the right angle or otherwise provide a smooth passageway for the cable through the boot, removing the end plug, inserting the ignition lead through the tool, and thereafter finishing the electrical terminal end by crimping in place on a reversely folded stripped end portion of the conductor. Thereafter the crimped end of the conductor is preferably positioned interiorly of the tubular body, and the tubular body and tool are withdrawn from the boot thereby finishing the ignition lead.

From the foregoing it will become apparent that one of the principal objects of the present invention is to provide a cable probe tool useful in making ignition leads which is inexpensive and readily available for any garage or service station, and a method for using the same to make in a minimum of time ignition leads comprising a wide variety of boots, nipples, ignition cable, and terminal connectors whether for spark plugs, distributors, or coils.

Yet another object of the present invention is to provide an ignition cable probe tool and method for using the same which, while light weight and manipulated manually, insures against unnecessary cutting and stripping of the ignition cable, terminal ends, and protective boots.

DESCRIPTION OF DRAWINGS Further objects and advantages of the present inven tion will become apparent as the following description of illustrative drawings proceeds in which:

FIG. I is a perspective view of the ignition cable probe tool, its end removed in one position, and the lubricant for using the same illustrated diagrammatically.

FIG. 2 is a longitudinal sectional view of the ignition cable probe tool inserted into a right angle spark plug boot.

FIG. 3 is a perspective partially cut away exploded view showing the ignition cable probe tool positioned for insertion into a spark plugboot of the right angle variety.

FIG. 4 is a view sequentially following FIG. 3 illustrating the ignition cable probe tool fully extended through and penetrating the right angle spark plug boot and prior to the insertion of the ignition cable.

FIG. 5 is a view sequential to that shown in FIG. 4 with the ignition cable extending throughthe tool, the end plug removed, and the cable stripped showing in phantom lines how the conductor portion of the cable is reversely folded over the cable end.

FIG. 6 is a view sequential to that of FIG. 5 showing the crimping of a tenninal in place on the ignition cable, in this instance a right angle spark plug terminal.

FIG. 7 illustrates a step in the method which includes reversing the position of the spark plug boot towards the handle portion of the tool and covering up the crimped end of the terminal by the far end of the tubular body of the tool.

FIG. 8 shows how the tool is thereafter removed and in phantom lines illustrates the end of the tubular body being withdrawn from the right angle spark plug terminal.

FIG. 9 is even a further sequential view of the step shown in FIG. 8 with the tool completely removed from the boot.

FIG. 10 is an exploded partially sectioned view illustrating the distributor terminal prior to electrical connection.

FIG. 11 shows the cable with its spark plug boot finished, the tool removed therefrom, and a distributor nipple inserted over the cable for receipt of an electrical terminal.

FIG. 12 is a longitudinal partially sectioned view of the completed ignition lead showing the spark plug terminal and boot at the right hand portion thereof and the distributor terminal and nipple at the left end portion thereof.

DESCRIPTION OF THE PREFERRED EMBODIMENT Ignition Cable Probe Tool A complet understanding of the invention including the tool and method of making an ignition lead can be best understood first by a reference in detail to the tool. Referring now to FIGS. 1 and 2 of the drawings, it will be seen that the ignition cable probe tool has an end plug 11, and a grip 15. The end plug 11, preferably made of plastic such as nylon or other smooth plastic having a high lubricity inherent in the composition of material, has a bullet-like heat 13. At the opposite end of the plug 1 1 is a body stud 14. It will be observed that the tubular body 12 of the ignition wire probe tool 10 is provided for a snug press plug fit with the body stud 14.

The grip 15 is shown in the configuration of an annular washer, but with the understanding that the grip 15 is provided primarily for pressing the tool 10 interiorly of a rubber-like member, such as a right angle spark plug boot, and removing the same, it will be appreciated that the configuration of the grip 15 in the annular form shown may be susceptible of modification to provide flanking finger holds, means for securing to a solid member or bench, and the like. Important to the utility of the tool 10, however, is a smooth exterior finish achieved such as by plating or fine buffing of the tubular body 12. Similarly the roundness and lubricity of the bullet head 13 of the end plug 11 is important and, as will be shown in the method, a lubricant 16 such as silicone is preferably applicable to the end plug 11. The interior of the tubular body 12 is dimensioned to loosefittingly receive ignition cable 18 (such as shown sequentially in FIGS. 3 through 5), and also dimensioned to receive the crimped end 31 of a right angle spark plug terminal 30 such as illustrated sequentially in FIGS. 6 and 7. Further consonant with the efforts to facilitate ingress to the rubber boot, and also prevent tearing or chafing, it will be observed that a rounded or radiused end 17 is provided on the tubular body 12 remote from the grip 15. The tubular body 12 is preferably metallic as well as the end grip 15 but it will be appreciated that certain plastics susceptible of being formed or extruded with thin walls may also be employed. In all events, a smooth finish, preferably achieved by plating when a metallic tubular body is formed, is highly desirable. Method of Making an Ignition Lead The method of making an ignition lead contemplates the use of a cable 18 which is preliminarily cut toapproximately l-% to l-k inches longer than the total length intended for the finished lead. A tubular tool, such as the tool 10 illustrated having a tubular body portion 12, is inserted into a lubricant 16 so that the end of the tubular body 12 will readily penetrate a spark plug boot 20. The spark plug boot 20 illustrated is of the right angle variety having a long leg 21, a short leg 22, and an elbow 24 joining the two legs 21, 22. As will be observed in FIG. 3, the ignition lead 18 is not inserted into the tool 10 until after the tool 10 has been thrust entirely through the spark plug boot 20 to the configuration illustrated in FIG. 4, and shown in cross sectional detail in FIG. 2.

Thereafter the ignition lead 18, as shown in FIG. 5, is inserted entirely through the tubular body of the tool 10, and the end of the cable 18 stripped thus exposing a stripped end 19 which is preferably reversely folded 6 over the insulating end portion of the cable 18, the re versely folded portion of the cable 19 being shown in phantom lines in FIG. 5, the end plug of the preferred embodiment tool 10 being shown in phantom-lines as having first been removed from the tubular body 12.

Thereafter, as illustrated in FIG. 6, a spark plug terminal is positioned over the reversely folded stripped end 19 of the cable 18 and crimped in place by means of an ignition lead crimper stripper tool 25. Preferably the terminal 30 is positioned within the jaws of the tool 25 and thereafter placed over the end of the cable 18 with the reversely folded conductor portion 19 against the uninterrupted portion of the crimping end of the terminal 30.

After the terminal 30 has been securely crimped in place and inspected so that the same is generally circular in cross section, the tool 10 is pressed forwardly with respect to the right angle spark plug boot 20 as shown in FIG..7, with the end of the tool 10 abutting the right angle terminal portion of the spark plug terminal 30.

Thereafter as shown in FIG. 8, the spark plug boot is pressed forwardly over the tool 10, the same being restrained by holding on to the grip 15. The end of the tubular body 12, as shown in FIG. 7, protects the boot 20 from the rough edges left by teh crimping of the crimped end 31 of the spark plug right angle terminal 30. In FIG. 8 the dotted lines show the tool 10 being partially removed, and thereafter in FIG. 9 it will be seen that the tool 10 may be pulled and completely removed from the cable 18, the opposite end of the cable to be finished thereafter for connection to the distributor (or magneto) or other electrical connection.

As shown in FIGS. 10 through 12, it will be seen that a distributor nipple 35 is slipped over the exposed end of the cable 18. Thereafter the distributor terminal is positioned for the insertion of its conductor spike 42 into the conductor portion of the cable 18, for securely clamping in place by means of the clamping wings 41, and particularly the one barb wing 44. When the distributor terminal 40 is clamped in place thusly it exposes at its far portion the contact end which is positioned in direct electrical contact with the distributor electrical connector. To assist in this respect, the distributor nipple 35 isprovided with a cup end 36 having interior ribs 37 which particularly receive and engage the upstanding portion of the distributor. The sleeve terminal 38 which engages the cable 18 immediately has an annular wiper portion 39 which seals the interior of the cup 36 from ambient dust, dirt, and water thereby providing, according to the method described above, a completed ignition lead such as shown in FIG. 12 ready for insertion at one end in electrical connection with a spark plug, and at the other end with a terminal on a distributor. Although particular embodiments of the invention have been shown and described in full here, there is no intention to thereby limit the invention to the details of such embodiments. On the contrary, the intention is to cover all modifications, alternatives, embodiments, usages and equivalents of an ignition cable probe tool and method of making ignition leads as fall within the spirit and scope of the invention, specification and the appended claims.

What is claimed is:

1. An ignition cable probe tool comprising in combination,

a tubular body,

said tubular body having an interior diameter to loose-fittingly receive an ignition cable,

an end plug,

said end plug having a rounded endof bullet-shaped configuration, and,

a stud end portion on said end plug at the end opposite the roundedend and proportioned to snugfittingly engage the tubular body and be removable inserted therein, and t a grip at the end of the tubular body opposite the end of the tubular body in which the end plug is inserted, whereby said ignition cable probe tool with the end plug in place can be inserted through an elastomeric right angle or straight ignition-type boot, the end plug removed and the lead wire inserted therethrough, a terminal secured to the end, and thereafter by holding the ignition cable probe tool grip the same can be removed from the boot and the ignition terminal completed.

2. In the ignition cable probe tool of claim 1,

said tubular body being a metal tube having a smooth exterior and thin walled cross section.

3. In the ignition cable probe tool of claim 1,

said end plug being formed of a plastic material having a high inherent lubricity property.

4. In the ignition cable probe tool of claim 1,

said grip being an annular member surrounding one end of the tubular body portion the plane of the same being substantially perpendicular to the longitudinal axis of the tubular body.

5. In the ignition cable probe tool of claim 2,

said end plug being formed of a plastic material having a high inherent lubricity property.

6. In the ignition cable probe tool of claim 2,

said grip being an annular member surrounding one end of the tubular body portion the plane of the same being substantially perpendicular to the longitudinal axis of the tubular body.

7. In the ignition cable probe tool of claim 3,

said grip being an annular member surrounding one end of the tubular body portion the plane of the same being substantially perpendicular to the longitudinal axis of the tubular body.

8. In the ignition cable probe tool of claim 5,

said grip being an annular member surrounding one end of the tubular body portion the plane of the same being substantially perpendicular to the longitudinal axis of the tubular body.

9. In the ignition cable probe tool of claim 2, the end of said tubular body intended for receiving said end plug having a rounded or radiused end. 10. The method of making an ignition lead from 5 cable having an exterior insulation and a central conductive portion comprising the steps of,

inserting a tubular ignition cable lead probe having a removable end plug into and through a boot of elastomeric properties, said tubular ignition cable lead probe having an interior diameter to loosefittingly receive an ignition cable, removing the end plug, cutting the cable to length, the length being approximately l-% to l-H inches longer than the finished length, inserting one end of the cable through the tubular probe so as to extend beyond the end thereof, stripping the end of said cable to expose a portion thereof which may be reversely folded over the end of the cable, reversely folding the central conductor portion of the cable over its end, positioning a terminal over said reversely folded por tion of the conductor with the reversely folded portion of the conductor contacting an uninterrupted conductive portion of the terminal, crimping said terminal around the end of the lead and holding the same to a substantially circular cross section of less than the interior of the tubular probe, moving the boot forwardly over the tubular probe after the tubular probe has been moved forwardly as far as possible over the terminal crimped portion,

removing the tubular probe after the boot has been aligned by moving the same forwardly over the tubular probe, and, thereafter withdrawing the tubular probe from the boot and completing the one terminal end.

11. In the method of claim 10 above, the additional step of:

lubricating the end plug of the tubular probe prior to inserting the same into the boot. 45 

1. An ignition cable probe tool comprising in combination, a tubular body, said tubular body having an interior diameter to loose-fittingly receive an ignition cable, an end plug, said end plug having a rounded end of bullet-shaped configuration, and, a stud end portion on said end plug at the end opposite the rounded end and proportioned to snug-fittingly engage the tubular body and be removably inserted therein, and a grip at the end of the tubular body opposite the end of the tubular body in which the end plug is inserted, whereby said ignition cable probe tool with the end plug in place can be inserted through an elastomeric right angle or straight ignition-type boot, the end plug removed and the lead wire inserted therethrough, a terminal secured to the end, and thereafter by holding the ignition cable probe tool grip the same can be removed from the boot and the ignition terminal completed.
 2. In the ignition cable probe tool of claim 1, said tubular body being a metal tube having a smooth exterior and thin walled cross section.
 3. In the ignition cable probe tool of claim 1, said end plug being formed of a plastic material having a high inherent lubricity property.
 4. In the ignition cable probe tool of claim 1, said grip being an annular member surrounding one end of the tubular body portion the plane of the same bEing substantially perpendicular to the longitudinal axis of the tubular body.
 5. In the ignition cable probe tool of claim 2, said end plug being formed of a plastic material having a high inherent lubricity property.
 6. In the ignition cable probe tool of claim 2, said grip being an annular member surrounding one end of the tubular body portion the plane of the same being substantially perpendicular to the longitudinal axis of the tubular body.
 7. In the ignition cable probe tool of claim 3, said grip being an annular member surrounding one end of the tubular body portion the plane of the same being substantially perpendicular to the longitudinal axis of the tubular body.
 8. In the ignition cable probe tool of claim 5, said grip being an annular member surrounding one end of the tubular body portion the plane of the same being substantially perpendicular to the longitudinal axis of the tubular body.
 9. In the ignition cable probe tool of claim 2, the end of said tubular body intended for receiving said end plug having a rounded or radiused end.
 10. The method of making an ignition lead from cable having an exterior insulation and a central conductive portion comprising the steps of, inserting a tubular ignition cable lead probe having a removable end plug into and through a boot of elastomeric properties, said tubular ignition cable lead probe having an interior diameter to loose-fittingly receive an ignition cable, removing the end plug, cutting the cable to length, the length being approximately 1-1/4 to 1- 1/2 inches longer than the finished length, inserting one end of the cable through the tubular probe so as to extend beyond the end thereof, stripping the end of said cable to expose a portion thereof which may be reversely folded over the end of the cable, reversely folding the central conductor portion of the cable over its end, positioning a terminal over said reversely folded portion of the conductor with the reversely folded portion of the conductor contacting an uninterrupted conductive portion of the terminal, crimping said terminal around the end of the lead and holding the same to a substantially circular cross section of less than the interior of the tubular probe, moving the boot forwardly over the tubular probe after the tubular probe has been moved forwardly as far as possible over the terminal crimped portion, removing the tubular probe after the boot has been aligned by moving the same forwardly over the tubular probe, and, thereafter withdrawing the tubular probe from the boot and completing the one terminal end.
 11. In the method of claim 10 above, the additional step of: lubricating the end plug of the tubular probe prior to inserting the same into the boot. 